Catalyst for purification of aromatic acids

ABSTRACT

One aspect of the invention relates to a catalyst composite containing an extruded catalyst support containing an extruded activated carbonaceous material having specifically a defined pore structure. For example, the extruded activated carbonaceous material may have pores wherein at least about 40% of total Hg porosity occurs in pores having a diameter of about 200 Å and larger. Alternatively the extruded activated carbonaceous material may have a first set of pores having a pore diameter of at least about 40 Å and at most about 100 Å with a porosity of at least about 0.15 cc/g, and a second set of pores having a pore diameter of at least about 5,000 Å and at most about 20,000 Å with a porosity of at least about 0.3 cc/g.

FIELD OF THE INVENTION

[0001] The present invention generally relates to catalyst compositescontaining extruded catalyst supports, and methods of making andemploying the catalyst composites. The present invention particularlyrelates to catalyst materials and methods associated with thepurification of terephthalic acid.

BACKGROUND OF THE INVENTION

[0002] Catalytic processes are indispensable in the chemical industry.Frequently, catalytic processes employ a catalyst that is incorporatedon a support. Effective use of the catalyst often corresponds to thequality of the catalyst support. Poor quality catalyst supports, due toat least one of physical degradation, chemical degradation, undesirableproperties, and inconsistent properties, limit the effectiveness ofcatalysts incorporated therein. Conditions such as high temperatures,high pressures, and high or low pH environments present challenges tothe integrity of catalyst supports.

[0003] For example, conventional catalyst composites for thepurification of terephthalic acid by the Amoco mid-continent process(PTA catalysts) are composed of palladium-supported on granular 4×8 meshcarbon. These catalyst composites are designed to remove the two majorimpurities present in crude terephtahlic acid; namely yellow color and4-carboxy benzaldehyde (4-CBA).

[0004] Carbon is the preferred support material for conventional PTAcatalysts because it is essentially the only readily available materialthat can simultaneously yield an effective catalyst for color removal,4-carboxy benzaldehyde removal, and also withstand the extremelycorrosive environment of the terephthalic acid purification process.Although conventional carbon supported PTA catalysts have been usedextensively over the past 20 years, such catalyst composites suffer fromseveral disadvantages. These disadvantages include: highly irregularshapes leading to possible mal-distribution of liquid or gas flows in acatalytic reactor bed utilizing such catalyst composites; irregularshapes having sharp and fragile edges and corners which tend to breakoff and contaminate the PTA product with undesirable dust and blackparticles; brittleness which also leads to breakage and dust/blackparticles contaminating the PTA product; natural origin, i.e., coconutshell, which leads to non-uniformity form one growing season to anotherand consequent non-consistency of the carbon support; and being commonlyderived from nutshells, such activated carbon is highly microporous,leading to the requirement of locating all of the active catalytic metalat the surface of the particles, where it is undesirably susceptible toloss during the movement and abrasion which occurs during shipping andhandling.

[0005] Particularly problematic is the unpredictable and uncontrollablemelange of irregular shapes and sizes associated with commonly employedgranular cocoanut carbon supports. Granular cocoanut carbons are alsomostly microporous; that is, they have numerous pores having a porediameter less than 50 Å. As a result, the catalytic metals must belocated near the exterior edges of the supports to avoid low activitydue to mass transfer resistances. However, when catalytic metals arelocated near the exterior edges of supports, they are subject to lossdue to mechanical attrition and thus the catalyst support loses itsactivity. Catalytic metals located near the exterior edges of a supportare readily accessible to corrosion metals commonly present in reactorfeeds and thus subject to deactivation.

[0006] Non-carbon catalyst supports are employed in catalytic processesin attempts to overcome the disadvantages associated with conventionalcarbon supported catalysts. Non-carbon supports include aluminasupports, silica supports, alumina-silica supports, various claysupports, titania, and zirconium supports. However, there are at leastone of two disadvantages associated with non-carbon catalyst supports;namely, that they may become weak and loose physical strength, that theyare dissolved in highly corrosive environments (such as hot aqueoussolutions of terephthalic acid) and that they have difficulties inremoving undesirable color from crude terephthalic acid.

[0007] Improved catalyst supports and catalyst composites are thereforedesired. Specifically, improved PTA catalyst supports and PTA catalystcomposites are desired to provide improved methods of purifyingterephthalic acid and improved useful lifetimes.

SUMMARY OF THE INVENTION

[0008] The present invention is designed to address at least one of andpreferably all of the above disadvantages by providing a catalystcomposite containing a composite support which is formed into shapeswith mesoporosity and macroporosity. The catalyst composites of thepresent invention enjoy an extended useful lifetime compared toconventional catalyst composites since they contain a support composedof an extruded carbonaceous material capable of withstanding harsh,corrosive reaction environments, such as those encountered in PTAcatalysis. In this connection, the catalyst composites of the presentinvention have a lower deactivation rate than conventional catalystcomposites. The catalyst composites of the present invention also enjoythe same or better activity with about 30% to about 50% by weight lessactive metal compared to conventional catalyst composites.

[0009] One aspect of the invention relates to a catalyst compositecontaining a metal catalyst and an extruded catalyst support containingan extruded activated carbonaceous material having specifically adefined pore structure. For example, the extruded activated carbonaceousmaterial may have pores wherein at least about 40% of total Hg porosityoccurs in pores having a diameter of about 200 Å or larger.Alternatively the extruded activated carbonaceous material may have afirst set of pores having a pore diameter of at least about 40 Å and atmost about 100 Å with a porosity of at least about 0.15 cc/g, and asecond set of pores having a pore diameter of at least about 5,000 Å andat most about 20,000 Å with a porosity of at least about 0.3 cc/g.

[0010] Another aspect of the invention relates to a method of making acatalyst composite involving mixing at least one carbonaceous materialand a liquid to form a mixture; extruding the mixture into a shapedmaterial; optionally drying the shaped material; heat treating theshaped material at a temperature from about 600° C. to about 1,500° C.to provide a catalyst support, wherein the catalyst support has at leastone of the two to four specifically a defined pore structures, andcontacting a precious metal catalyst with the catalyst support.

[0011] Yet another aspect of the invention relates to a method ofpurifying a crude polycarboxylic aromatic acid composition involvingcontacting the crude polycarboxylic aromatic acid composition with acatalyst composite containing a metal catalyst and an extruded activatedcarbonaceous material having at least one of the two to fourspecifically a defined pore structures. And still yet another aspect ofthe invention relates to a method of purifying a crude amine compositionor a crude alkynol amine composition involving contacting the crudeamine composition or the crude alkynol amine composition with a catalystcomposite containing a catalyst support containing a metal catalyst andan extruded activated carbonaceous material having at least one of thetwo to four specifically a defined pore structures.

BRIEF SUMMARY OF THE DRAWINGS

[0012]FIG. 1 shows a graph of pore diameter distribution of conventionalgranular carbon and extruded carbon in accordance with one aspect of thepresent invention.

[0013]FIG. 2 shows a graph of pore diameter distribution of severalconventional granular carbons and several embodiments of extruded carbonin accordance with one aspect of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0014] In one embodiment, the present invention involves the preparationof catalyst composites containing an extruded carbon catalyst support.The extruded catalyst support is particularly suited for metalcatalysts, especially palladium or platinum. The process according tothe present invention of preparing the extruded catalyst support mayinvolve the mixing of a carbonaceous material and optional additives. Aliquid is preferably added to the mix to give a stiff dough which isthen extruded (or pelletized or spheridized), optionally dried and heattreated to provide a material having at least one of two porestructures. After heat treatment of the extruded and optionally driedmaterial, impregnation with an active metal catalyst is conducted. Inanother embodiment, the present invention involves the use of a catalystcomposite in a catalytic process, such as in the purification of crudeterephthalic acid.

[0015] The extruded carbon catalyst support contains a carbonaceousmaterial, and optionally one or more additives. The carbonaceousmaterial may be derived from any suitable carbon source. Thecarbonaceous material initially used is an activated carbon, or anon-activated carbon that may be converted to activated carbon at somepoint during the formation of the extruded carbon catalyst support. Forexample, charcoal (a non-activated carbonaceous material) may beconverted to activated carbon during the heat treatment step(subsequently described). Carbonaceous materials include activatedcarbon derived from coal, lignite, wood, nutshells, peat, pitches,cokes, and the like; and non-activated carbon derived from carbon charpowder (e.g. charcoal).

[0016] The carbonaceous material combined with any optional additives istypically in powder form. In one embodiment, the carbonaceous materialhas a particle size (average particle size) of less than about 100microns. In another embodiment, the carbonaceous material has a particlesize of less than about 80 microns. In yet another embodiment, thecarbonaceous material has a particle size of less than about 50 microns.In still yet another embodiment, the carbonaceous material has aparticle size of less than about 25 microns.

[0017] Carbonaceous materials are commercially available or they may bemade. For example, carbonaceous materials may be derived from coal,coke, coal coke, petroleum coke, lignite, polymeric materials, graphite,bone, wood, nut shells including coconut shells, resin wastes,lignocellulosic materials including pulp and paper, kernel, fruit pits,and sugar. The source of carbonaceous materials is not critical to thepresent invention. Consequently, another advantage associated with thepresent invention is that the source of carbonaceous materials is notcritical. U.S. Pat. Nos. 3,084,394; 3,109,712; 3,171,720; 3,198,714;3,310,611; 3,387,940; 3,342,555; 3,345,440; 3,352,788; 3,446,593;3,565,980; 3,574,548; 3,626,042; 3,628,984; 3,634,569; 3,635,676;3,663,171; 3,859,421; 4,029,567; 4,082,694; 4,206,078; 4,263,268;4,329,260; 4,603,119; 4,668,496; 4,954,469; 4,987,116; describe variouscarbonaceous materials and are hereby incorporated by reference in thisregard.

[0018] The carbonaceous materials are chemically activated ornon-chemically activated. Chemical activating agents include one or moreof alkali metal hydroxides, alkali metal carbonates, alkali metalsulfide, alkali metal sulfates, alkaline earth metal carbonates,alkaline earth metal chlorides, alkaline earth metal sulfates, alkalineearth metal phosphates, phosphoric acid, polyphosphoric acid,pyrophosphoric acid, zinc, chloride, sulfuric acid, and the like.Chemical activation is conducted by contacting one or more carbonaceousmaterials with one or more chemical activating agents, mixing,optionally heating, optionally washing/rinsing, and optionally dryingthe chemically activated material.

[0019] In one embodiment, the extruded carbon catalyst support containsabout 50% by weight or more and about 100% by weight or less of at leastone carbonaceous material. In another embodiment, the extruded carboncatalyst support contains about 60% by weight or more and about 99.9% byweight or less of at least one carbonaceous material. In yet anotherembodiment, the extruded carbon catalyst support contains about 70% byweight or more and about 99% by weight or less of at least onecarbonaceous material. In still yet another embodiment, the extrudedcarbon catalyst support contains about 75% by weight or more and about95% by weight or less of at least one carbonaceous material.

[0020] Extruded carbon catalyst supports are commercially available. Forexample, extruded carbon materials are available from Ceca, Norit,Westvaco, and Takeda. Alternatively, the extruded carbon catalystsupport may be made by mixing the carbonaceous material and any optionaladditives, forming the mixture into a shaped material, optionally dryingthe shaped material, and heat treating the shaped material to providethe hard, extruded carbon catalyst support. When mixing the carbonaceousmaterial and any optional additives, it is preferable to add water(and/or other liquid solvent). Tap water or deionized water may beemployed, but deionized water is preferred. Water is added to facilitatemixing and subsequent forming (for instance, extrusion), and thus it isadded in any amount suitable to facilitate mixing and subsequentforming. Since water is eventually removed in subsequent drying and heattreatment steps, the amount of water added is not critical to thepresent invention.

[0021] Nevertheless, in one embodiment, the mixture of optionaladditives and carbonaceous material typically contains from about 5% toabout 80% by weight water. In another embodiment, the mixture ofoptional additives and carbonaceous material contains from about 10% toabout 70% by weight water. In another embodiment, the mixture ofoptional additives and carbonaceous material contains from about 20% toabout 60% by weight water.

[0022] Additives include any material that facilitates mixing andsubsequent forming. Additives include rheology control agents, extrusionaids, suspension agents, surfactants, low boiling organic compounds,rosin materials, polymeric additives, dispersing agents such as ammoniumlignosulfonates, and metal nitrates, sulfates, carbonates, phosphates,hydroxides, and oxides. Rheology control agents include celluloseethers, polyvinyl alcohols, and polyalkylene oxides. Examples ofcellulose ethers include sodium carboxymethylcellulose (CMC),hydroxyethylcellulose (HEC), methylcellulose (MC) and derivativesthereof. One commercially available cellulose ether is Methocel.Methocel, which contains water and hydroxypropylmethylcellulose etherpolymer, has a high thermal gelatin point, such as the productsdesignated as K4M and K15M available from Dow Chemical Company.Preferred polyalkylene oxides include polyethylene oxides. Extrusionaids include glycol compounds, such as polyalkylene glycols. In aspecific embodiment, polyethylene glycol, such as PEG 400 available fromUnion Carbide can be added as an extrusion aid. Generally, the glycolcompounds are dissolved in water and then added to the dry ingredients.

[0023] In one embodiment, the extruded carbon catalyst support typicallycontains from about 0.01% to about 10% by weight of at least oneadditive. In another embodiment, the extruded carbon catalyst supportcontains from about 0.1% to about 5% by weight of at least one additive.

[0024] The mixture of carbonaceous powder and any optional ingredientsmay be mixed well in a high shear mixer with water and a rheologycontrol agent, such as Methocel until a rather stiff dough is obtained.This dough can be extruded and formed into any suitable shape includingcylinders, cubes, stars, tri-lobes, quadra-lobes, pellets, spheres bysuitable mechanical means. In one embodiment, mixing is conducted in ahigh intensity environment, such as that supplied by a Littleford Mixeravailable from Littleford Day, Inc., Florence, Ky. Mixing is conductedfor a time sufficient so that a fine uniform mix results. In anotherembodiment, deionized water is added to the mixture during mixing in anamount to yield a stiff, dough-like material suitable for extrusion.

[0025] In one embodiment, the mixture of carbonaceous material andoptional additives is mixed in a high intensity mixer from about 5minutes to about 100 minutes. In another embodiment, mixture ofcarbonaceous material and optional additives is mixed in a highintensity mixer from about 10 minutes to about 60 minutes. In yetanother embodiment, mixture of carbonaceous material and optionaladditives is mixed in a high intensity mixer from about 15 minutes toabout 40 minutes.

[0026] After mixing, the mixed material is extruded into a suitableshape. The shape substantially corresponds to the shape of the resultantcatalyst support. In a preferred embodiment, the mixed material isextruded in a continuous manner over a broad range of diameters andshapes. Examples of forming or extrusion machines include extrusionmolding machines, single screw extruders, twin screw extruders,coextruders, pin extruders, linear extruders, and monofilamentextruders.

[0027] The extruded material is then optionally formed into any desiredshape. Examples of forming machines include molding machines, tabletingmachines, rolling granulators, marumarizers, and pelletors. The shape ofthe extruded material includes spheres, tablets, cylinders, stars,tri-lobes, quadra-lobes, pellets, granules, honeycombs, and cubes. Theshapes, generally referred to as “particulate”, may have any suitablesize. However, in a preferred embodiment, the sizes of the shapes aresubstantially uniform. In another preferred embodiment, the mixedmaterial is extruded into cylindrical shapes having diameters from about1.5 mm to about 3.5 mm.

[0028] The extruded material has its components (the carbonaceousmaterial and any optional additives) uniformly mixed therein. Uniformlymixed optional additives and carbonaceous material in the subsequentresultant catalyst support contributes to the advantageous properties ofthe resultant extruded catalyst support and resultant catalyst compositecontaining the catalyst support.

[0029] After extruding the material into a desired shape, the extrudedmaterial is optionally dried to remove any remaining liquid (andtypically to remove remaining water). Drying is conducted in at leastone of a desiccator, under a vacuum (reduced pressure), and/or elevatedtemperature (baking) for a sufficient period of time to remove anyremaining liquid from the formed material. Drying the extruded materialcontributes to the attrition resistance properties of the resultantextruded carbon catalyst support.

[0030] The manner in which the extruded material is dried is notcritical, but in many instances the drying conditions primarily dependupon at least one of the dimensions of the extruded material, the shapeof the extruded material and the manner in which the extruded materialis held. In one embodiment, the dried extruded material contains lessthan about 3% by weight free moisture. In another embodiment, the driedextruded material contains less than about 1% by weight free moisture.In yet another embodiment, the dried extruded material contains lessthan about 0.5% by weight free moisture.

[0031] In one embodiment, drying involves at least one of maintaining anelevated temperature (above about 35° C.) overnight, desiccationovernight, and under a vacuum overnight. When employing elevatedtemperatures, in one embodiment, the extruded material is heated fromabout 35° C. to about 150° C. for a time from about 5 seconds to about 6hours. In another embodiment, the extruded material is heated from about40° C. to about 110° C. for a time from about 30 seconds to about 30minutes. In yet another embodiment, the extruded material is heated fromabout 50° C. to about 90° C. for a time from about 1 minute to about 20minutes. In a preferred embodiment, the extruded material is subjectedto a ramped drying process (two step drying process), with the initialdrying temperature from about 40° C. to about 95° C., and morepreferably from about 60° C. to about 85° C., and then heated to atleast about 100° C., and more preferably at least about 110° C., tocomplete the drying process.

[0032] After drying, the extruded material is heat treated. However, inone embodiment, the drying step may be incorporated into the heattreatment step by starting the heat treatment at a relatively lowtemperature (low temperatures relative to the heat treatmenttemperatures). The dried and extruded material is heat treated in anysuitable manner to provide a hard catalyst support and to provide acatalyst support containing a carbonaceous material having propertiescorresponding with those of activated carbon (especially in embodimentswhere a non-activated carbonaceous material is employed).

[0033] In one embodiment, heat treatment involves heating the extrudedmaterial at a temperature from about 600° C. to about 1,500° C. Inanother embodiment, heat treatment involves heating the extrudedmaterial at a temperature from about 700° C. to about 1,000° C. In yetanother embodiment, heat treatment involves heating the extrudedmaterial at a temperature from about 800° C. to about 900° C. It isnoted that the temperature may vary within a temperature range. Forexample, the temperature may be ramped or steadily increased during thelength of the heat treatment.

[0034] The length of time the extruded material is heated primarilydepends upon the temperature, the contents of atmosphere, the size ofthe extruded material, the related equipment, and the identity of thecomponents (the specific type of carbonaceous material and the optionaladditives). In one embodiment, heat treatment involves heating theextruded material from about 15 minutes to about 5 hours. In anotherembodiment, heat treatment involves heating the extruded material fromabout 30 minutes to about 4 hours. Heating time refers to the amount oftime that the extruded material itself is at the temperature specified(and thus does not include ramping up or cooling down).

[0035] In one embodiment, the atmosphere in which the heat treatment isconducted contains at least steam or water vapor. The atmosphere mayfurther contain at least one of an inert gas, air, oxygen, and carbondioxide. Inert gases include the noble gases and nitrogen. Noble gasesinclude helium, neon, argon, krypton, and xenon. In another embodiment,the atmosphere in which the heat treatment is conducted contains atleast one of steam/water vapor and an inert gas. In this connection, inone embodiment, the heat treatment atmosphere contains a substantiallyinert atmosphere, such as from about 50% to about 100% of at least onean inert gas and from about 0% to less than about 50% of one or more ofsteam, air, oxygen, and carbon dioxide. In a preferred embodiment, theheat treatment atmosphere contains steam and nitrogen.

[0036] In one embodiment, the heat treatment atmosphere contains fromabout 5% to about 100% steam and from 0% to about 95% of at least one ofan inert gas, air, oxygen, and carbon dioxide. In another embodiment,the heat treatment atmosphere contains from about 20% to about 95% steamand from about 5% to about 80% of at least one of an inert gas, air,oxygen, and carbon dioxide. In yet another embodiment, the heattreatment atmosphere contains from about 30% to about 90% steam and fromabout 10% to about 70% of at least one of an inert gas, air, oxygen, andcarbon dioxide.

[0037] After heat treatment, the optionally dried, extruded product iscooled in any suitable manner. In one embodiment, the optionally dried,extruded product is cooled under an atmosphere containing an inert gas.

[0038] The resultant extruded carbon catalyst supports of the presentinvention possess a level of porosity is that controllable, primarily byvarying the heat treatment parameters and by varying the relativeamounts of the ingredients (the carbonaceous material and the optionaladditives). Porosity may also be controllable or is further controllableby the amount and the type of additive, such as the rheology controlagent or the extrusion aid.

[0039] In one embodiment, the extruded carbon catalyst supports of thepresent invention have a bulk density from about 400 grams per liter toabout 1,000 grams per liter. In another embodiment, the extruded carboncatalyst supports have a bulk density from about 425 grams per liter toabout 750 grams per liter. In yet another embodiment, the extrudedcarbon catalyst supports have a bulk density from about 440 grams perliter to about 600 grams per liter.

[0040] Generally, the surface area of the extruded carbon catalystsupports of the present invention correspond to a weighted average ofthe surface area of the optional additives and carbonaceous material. Inone embodiment, the surface area of the extruded carbon catalystsupports is about 300 m²/g or more and about 1,600 m²/g or less. Inanother embodiment, the surface area of the extruded carbon catalystsupports is about 800 m²/g or more and about 1,400 m²/g or less.

[0041] The extruded carbon catalyst supports generally have a uniquedistribution of pore sizes that contributes to the advantages obtainedby the present invention. While not wishing to be bound by any theory,it is believed that the minimum surface area and/or distribution of poresizes in extruded carbon catalyst supports of the present inventioncontributes to improved aging (by maximizing porosity in pore sizes ofabout 200 Å or larger, such as at least about 40% porosity in pore sizesof about 200 Å or larger or at least about 38% porosity in pore sizes ofabout 1,000 Å or larger); improved HMBA/toluic acid ratios; improved CBAremoval and/or improved yellow color removal.

[0042] In one embodiment, the extruded carbon catalyst has a pore sizedistribution wherein a first set of pores containing a porosity of atleast about 0.15 cc/g have a pore diameter of at least about 40 Å and atmost about 100 Å, and a second set of pores containing a porosity of atleast about 0.3 cc/g have a pore diameter of at least about 5,000 Å andat most about 20,000 Å (Hg intrusion porosimetry, such as using aMicromeritics model AutoPore-II 9220 porosimeter in accordance with theanalysis method outlined in one or more of U.S. Pat. Nos. 5,186,746;5,316,576; and 5,591,256). In another embodiment, the extruded carboncatalyst has a pore size distribution wherein a first set of porescontaining a porosity of at least about 0.2 cc/g have a pore diameter ofat least about 40 Å and at most about 100 Å, and a second set of porescontaining a porosity of at least about 0.4 cc/g have a pore diameter ofat least about 5,000 Å and at most about 20,000 Å.

[0043] Referring to FIG. 1, the pore structure of a typical,conventional granular coconut carbon (Pica G202X) is compared with anextruded carbon (Takeda S2X) in accordance with one embodiment of thepresent invention. The pore volume distribution of the extruded carbonin accordance with the present invention is weighted much more heavilyin larger pores whereas the conventional granular coconut carbon isweighted in relatively small pores. For this reason, the conventionalgranular coconut carbon is referred to as microporous, whereas theextruded carbon in accordance with the present invention may be referredto mesoporous and macroporous.

[0044] Referring to FIG. 2, the pore structure of four typical,conventional granular coconut carbons are compared with five differentembodiments of the extruded carbons in accordance with the presentinvention. In the graph, conventional granular coconut carbons includeGranular TA-485E available from Pica, Granular G202X available fromPica, Granular 206CAT available from Barneby-Waterlink, and Granular NCAavailable from Pica. Extruded carbons include Extruded AC40/3 availablefrom Ceca, Extruded RX3 Extra available from Norit, Extruded S2Xavailable from Takeda, Extruded G2X available from Takeda, and ExtrudedC2X available from Takeda. The pore volume distribution of the extrudedcarbons in accordance with the present invention is weighted much moreheavily in larger pores whereas the conventional granular coconut carbonis weighted in relatively small pores. For example, as seen from thegraph, at least about 40% of total Hg porosity occurs in pores having adiameter of about 200 Å and larger, such as about 1,000 Å and larger.

[0045] In Table 1 below, the amount (% by weight) of palladium in acatalyst composite and corresponding 4-CBA removal rates are reported.The 4-CBA removal rate is the ratio of the first order 4-CBA removalrate for the subject catalyst composite divided by the first order 4-CBAremoval rate for a conventional standard catalyst composite (catalystcomposite containing a Pica G202X support). The catalyst compositesaccording to the present invention (containing the Takeda C2X or CecaAC40/3 based composite) exhibit improved 4-CBA removal rates compared toa standard catalyst composite (catalyst composite containing a PicaG202X support). TABLE 1 catalyst support % Pd 4-CBA removal rate TakedaC2X 0.5 1.25 Takeda C2X 0.35 1.11 Takeda C2X 0.25 0.95 Ceca AC40/3 0.51.2 Ceca AC40/3 0.35 1.15 Pica G202X 0.5 1.0

[0046] In one embodiment, the extruded carbon catalyst has a pore sizedistribution wherein at least about 40% of total Hg porosity occurs inpores having a diameter of about 200 Å and larger (Hg intrusionporosimetry). In another embodiment, the extruded carbon catalyst has apore size distribution wherein at least about 38% of total Hg porosityoccurs in pores having a diameter of about 1,000 Å and larger. In yetanother embodiment, the extruded carbon catalyst has a pore sizedistribution wherein at least about 34% of total Hg porosity occurs inpores having a diameter of about 5,000 Å and larger.

[0047] In one embodiment, the extruded carbon catalyst has anHMBA/toluic acid ratio at the end of a run of at least about 2.5. TheHMBA/toluic acid ratio at the end of a run is the ratio of4-hydroxymethyl benzoic acid to toluic acid present at the end of a testpurification reaction (in the feed, the HMBA/toluic acid ratio is about0.44). In another embodiment, the extruded carbon catalyst has anHMBA/toluic acid ratio at the end of a run of at least about 2.75. Inyet another embodiment, the extruded carbon catalyst has an HMBA/toluicacid ratio at the end of a run of at least about 3. In still yet anotherembodiment, the extruded carbon catalyst has an HMBA/toluic acid ratioat the end of a run of at least about 3.25.

[0048] The extruded carbon catalysts of the present invention generallyhave a longer life compared to a conventional granular carbon catalysts.In other words, the extruded carbon catalysts of the present inventiongenerally have a lower deactivation rate than conventional granularcarbon catalysts. For example, in one embodiment, the extruded carboncatalyst of the present invention containing 0.5% by weight metalcatalyst has about a 1.5 times or more longer life than a conventionalgranular carbon catalyst containing 0.5% by weight of the same metalcatalyst. In another embodiment, the extruded carbon catalyst of thepresent invention containing 0.5% by weight metal catalyst has about a 2times or more longer life than a conventional granular carbon catalystcontaining 0.5% by weight of the same metal catalyst.

[0049] In yet another embodiment, the extruded carbon catalyst of thepresent invention has a deactivation rate that is about 25% or morelower than the deactivation rate of a similarly loaded (same amount ofsame metal catalyst) conventional granular carbon catalyst. In still yetanother embodiment, the extruded carbon catalyst of the presentinvention has a deactivation rate that is about 50% or more lower thanthe deactivation rate of a similarly loaded conventional granular carboncatalyst.

[0050] Since the extruded carbon catalysts of the present invention havea lower deactivation rate than similarly loaded conventional granularcarbon catalysts, the activities of the extruded carbon catalysts of thepresent invention are higher after various levels of aging compared toconventional granular carbon catalysts. In one embodiment, the extrudedcarbon catalyst of the present invention has an activity that is atleast about 1.5 times higher than a similarly loaded conventionalgranular carbon catalyst after 6 months, 12 months, or 18 months ofaging. In another embodiment, the extruded carbon catalyst of thepresent invention has an activity that is at least about 2 times higherthan a similarly loaded conventional granular carbon catalyst after 6months, 12 months, or 18 months of aging.

[0051] The extruded carbon catalysts of the present invention with lowmetal loading generally can perform equal to or even better than aconventional granular carbon catalysts with high metal loading. Forexample, in one embodiment, the extruded carbon catalyst of the presentinvention containing 0.25% by weight metal catalyst has an activityequal to or higher than a conventional granular carbon catalystcontaining 0.5% by weight of the same metal catalyst. In anotherembodiment, the extruded carbon catalyst of the present inventioncontaining 0.35% by weight metal catalyst has an activity equal to orhigher than a conventional granular carbon catalyst containing 0.5% byweight of the same metal catalyst.

[0052] In one embodiment, the present invention involves forming acatalytic composite by impregnating the extruded carbon catalyst supportwith a solution of at least one catalytically active metal. Theimpregnation is effected by treating the extruded carbon catalystsupport with an aqueous or organic solution of the desired metal orcombination of metals in an amount sufficient to deposit at least onecatalytically active metal on or near the surface of the support,thereby providing a catalyst composite.

[0053] Catalytically active metals typically include precious metals.Examples of catalytically active metals and mixture of metals includeplatinum, platinum and rhenium, platinum and ruthenium, platinum andtungsten, platinum and nickel, platinum and tin, platinum and iron,platinum and copper, platinum and rhodium, platinum and lead, platinumand germanium, platinum and gold, platinum and tellurium, palladium andgold, palladium and indium, palladium and sulfur, palladium andtellurium, palladium, palladium and rhenium, palladium and rhodium,palladium and tungsten, palladium and nickel, palladium and tin,palladium and copper, palladium and ruthenium, palladium and lead,palladium and germanium, cobalt, rhodium, ruthenium, osmium, iridium,various combinations thereof, etc. It is to be understood that theaforementioned list of catalytically active metals are onlyrepresentative, and thus not limiting of the type of metals which may beimpregnated on the catalytic support surface.

[0054] The catalyst may be impregnated onto/into the extruded carboncatalyst support in any suitable manner. For example, immersiontechniques, spraying techniques, and incipient wetness techniques may beemployed. In one embodiment, the amount of catalyst in the catalystcomposite is from about 0.01% to about 30% by weight. In anotherembodiment, the amount of catalyst in the catalyst composite is fromabout 0.1% to about 10% by weight. In yet another embodiment, the amountof catalyst in the catalyst composite is from about 0.2% to about 5% byweight. In one embodiment, the amount of the extruded carbon catalystsupport in the catalyst composite is from about 70% to about 99.99% byweight. In another embodiment, the amount of the extruded carboncatalyst support in the catalyst composite is from about 90% to about99.9% by weight. In yet another embodiment, the amount of the extrudedcarbon catalyst support in the catalyst composite is from about 95% toabout 99.8% by weight.

[0055] The extruded carbon catalyst supports and catalyst composites ofthe present invention are suitable for use in catalytic processes.Catalytic processes where the extruded carbon catalyst supports andcatalyst composites of the present invention can be employed includehydrogenation, rearrangement, purification, dehydration,dehydrogenation, oxidation, reduction, polymerization,dehydrocylcization, reforming, hydrocracking, and isomerization. Thespecific catalytic reactions/processes are too numerous to list, but thefollowing are specific examples.

[0056] The extruded catalyst composite of the present invention issuitable for use in purification of relatively impure or crudepolycarboxylic aromatic acids, particularly crude terephthalic acid,isophthalic acid, phthalic acid and naphthalene dicarboxylic acid. Theextruded catalyst composite of the present invention is also suitablefor use in purification of amines and alkynol amines, and particularlyaromatic amines, aromatic alkynol amines, aliphatic amines, andaliphatic alkynol amines.

[0057] In one embodiment, the impure polycarboxylic aromatic acid is acrude product of the catalytic oxidation of an aromatic compound.Examples of suitable aromatic compounds include 1,2-dimethylnaphthalene;2,6-dialkyl-naphthalene; 2-acyl-6-alkylnaphthalene;2,6-dimethylnaphthalene, 2,6-diethylnaphthalene;2,6-diisopropylnaphthalene; 2-acetyl-6-methylnaphthalene;2-methyl-6-ethyl naphthalene; para-dialkylxylene; meta-dialkylxylene;and ortho-dialkylxylene; wherein the alkyl groups contain from 1 toabout 6 carbon atoms. In a preferred embodiment, the crude acid purifiedin accordance with the present invention is at least one of terephthalicacid formed by the oxidation of para-xylene, isophthalic acid formed bythe oxidation of meta-xylene and 2,6-naphthalene dicarboxylic acidformed by the oxidation of 2,6-dialkylnaphthalene (preferably2,6-dimethyl naphthalene). In another embodiment, the crudepolycarboxylic aromatic acid, such as 2,6-naphthalene dicarboxylic acid,is made by esterification to form the corresponding ester, in this casedimethyl naphthalene dicarboxylate, and then hydrolyzation to form thepolycarboxylic aromatic acid which is then purified in accordance withthe present invention.

[0058] Methods of catalytically purifying crude polycarboxylic aromaticacids including terephthalic acid are known. For example, U.S. Pat. Nos.3,607,921; 3,887,613; 3,919,306; 4,260,817; 4,281,179; 4,317,923;4,394,299; 4,415,479; 4,447,646; 4,605,763; 4,629,715; 4,791,226;4,803,295; 4,808,751; 4,892,972; 4,937,378; 5,180,849; 5,362,908;5,420,344; 5,616,792; 5,723,659; 5,756,833; describe various methods ofcatalytically purifying crude polycarboxylic aromatic acids andparticularly terephthalic acid and are hereby incorporated by referencefor their teachings in this regard. Methods of catalytically purifyingcrude amines and alkynol amines, and particularly aromatic amines andaromatic alkynol amines, are known. In this connection, the catalystcomposite according to the present invention may be used in suchmethods.

[0059] In one embodiment, the catalyst composite is contacted with anaqueous solution or relatively impure or crude terephthalic acid thatincludes relatively large amounts of impurities such as 4-carboxybenzaldehyde and undesirable coloring. Such impurities are typicallypresent in amounts up to about 10,000 parts per million parts ofterephthalic acid, by weight (although higher amounts are encountered insome instances). These impurities adversely affect subsequentterephthalic acid polymerization reactions to produce polyethyleneterephthalate, as well as cause undesirable coloring of the resultingpolyethyleneterephthalate polymers.

[0060] In this embodiment, the catalyst composite is contacted with anaqueous solution of relatively impure or crude terephthalic acid at anelevated temperature and pressure in a fixed catalyst bed. The crudeterephthalic acid to be purified is dissolved in water or a like polarsolvent. Water is a preferred solvent; however, other suitable polarsolvents include the relatively lower molecular weight alkyl carboxylicacids, alone or admixed with water.

[0061] In one embodiment, the temperature during catalytic purificationis from about 100° C. to about 350° C. In another embodiment, thetemperature during catalytic purification is from about 225° C. to about340° C.

[0062] The pressure primarily depends upon the temperature at which thepurification process is carried out. Inasmuch as the temperatures atwhich practical amounts of the impure terephthalic acid may be dissolvedare substantially above the normal boiling point of the polar solvent,the pressures are necessarily considerably above atmospheric pressure tomaintain the aqueous solution in liquid phase. If the reactor ishydraulically full, the reactor pressure can be controlled by the feedpumping rate. In one embodiment, the pressure during hydrogenation isfrom about 150 pounds per square inch guage (psig) to about 1600 psig.In another embodiment, the pressure during hydrogenation is from about900 psig to about 1,200 psig.

[0063] In the operating mode where process control is effected byadjusting the hydrogen partial pressure, the hydrogen partial pressurein the reactor preferably is from about 10 psig to about 800 psig, fromabout 100 psig to about 600 psig, or higher, depending upon the servicepressure rating of the reactor, the degree of contamination of theimpure terephthalic acid, the activity and age of the particularcatalyst employed, and like processing considerations. When purifyingimpure or crude terephthalic acid, in one embodiment, the reactoratmosphere contains from about 10% to about 40% by weight hydrogen andfrom about 60% to about 90% by weight water vapor. In anotherembodiment, when purifying impure or crude terephthalic acid, thereactor atmosphere contains from about 15% to about 35% by weighthydrogen and from about 65% to about 85% by weight water vapor.

[0064] In the operating mode where process control is effected byadjusting directly the hydrogen concentration in the feed solution, thelatter usually is less than saturated with respect to hydrogen and thereactor itself is hydraulically full. Thus, an adjustment of thehydrogen flow rate to the reactor will result in the desired control ofhydrogen concentration in the solution. In general, an amount ofhydrogen that is sufficient to effect the desired hydrogenation underthe reaction conditions employed is supplied to the purificationreactor.

[0065] In one embodiment, activity rates for the removal of 4-carboxybenzaldehyde with a 0.5% by weight Pd catalyst composites (made of Pd onthe extruded carbon catalyst supports) of the present invention are fromabout 1 hr⁻¹ to about 2.6 hr⁻1. In another embodiment, activity ratesfor the removal of 4-carboxy benzaldehyde with a 0.5% by weight Pdcatalyst composites of the present invention are from about 1.1 hr⁻¹ toabout 2.2 hr⁻¹.

[0066] Color removal efficiencies for catalyst composites are measuredvia ultraviolet adsorption at 340 nm. In one embodiment, the catalystcomposites of the present invention remove at least about 75% of colorfrom crude terephthalic acid. In another embodiment, the catalystcomposites of the present invention remove at least about 80% of colorfrom crude terephthalic acid. In yet another embodiment, the catalystcomposites of the present invention remove at least about 90% of colorfrom crude terephthalic acid.

[0067] While the invention has been explained in relation to certainembodiments, it is to be understood that various modifications thereofwill become apparent to those skilled in the art upon reading thespecification. Therefore, it is to be understood that the inventiondisclosed herein is intended to cover such modifications as fall withinthe scope of the appended claims.

What is claimed is:
 1. A catalyst composite comprising: an extrudedcatalyst support comprising an extruded activated carbonaceous materialhaving pores and wherein at least about 40% of total Hg porosity occursin pores having a diameter of about 200 Å and larger; and a preciousmetal catalyst.
 2. A catalyst composite comprising: an extruded catalystsupport comprising an extruded activated carbonaceous material havingpores and wherein at least about 38% of total Hg porosity occurs inpores having a diameter of about 1,000 Å and larger; and a preciousmetal catalyst.
 3. A catalyst composite comprising: an extruded catalystsupport comprising an extruded activated carbonaceous material havingpores and wherein at least about 34% of total Hg porosity occurs inpores having a diameter of about 5,000 Å and larger; and a preciousmetal catalyst.
 4. The catalyst composite according to claim 3, whereinthe catalyst composite comprises about 70% by weight or more and about99.99% by weight or less of the extruded catalyst support and about0.01% by weight or more and about 30% by weight or less of the preciousmetal catalyst.
 5. A catalyst composite comprising: an extrudedactivated carbonaceous material comprising a first set of pores having apore diameter of at least about 40 Å and at most about 100 Å with aporosity of at least about 0.15 cc/g, and a second set of pores having apore diameter of at least about 5,000 Å and at most about 20,000 Å witha porosity of at least about 0.3 cc/g; and a precious metal catalyst. 6.The catalyst composite according to claim 5, wherein at least about 40%of total Hg porosity occurs in a third set of pores having a diameter ofabout 200 Å and larger in the extruded activated carbonaceous material.7. The catalyst composite according to claim 5, wherein the catalystcomposite comprises about 70% by weight or more and about 99.99% byweight or less of the extruded activated carbonaceous material and about0.01% by weight or more and about 30% by weight or less of the preciousmetal catalyst.
 8. The catalyst composite according to claim 5, whereinthe catalyst composite is at least one of a hydrogenation catalystcomposite, a rearrangement catalyst composite, a purification catalystcomposite, a dehydration catalyst composite, a dehydrogenation catalystcomposite, an oxidation catalyst composite, a reduction catalystcomposite, a polymerization catalyst composite, a dehydrocylcizationcatalyst composite, a reforming catalyst composite, a hydrocrackingcatalyst composite, and an isomerization catalyst composite.
 9. Thecatalyst composite according to claim 5, wherein the precious metalcatalyst comprises at least one selected from the group of platinum,platinum and rhenium, platinum and ruthenium, platinum and tungsten,platinum and nickel, platinum and tin, platinum and iron, platinum andcopper, platinum and rhodium, platinum and lead, platinum and germanium,palladium, palladium and rhenium, platinum and gold, platinum andtellurium, palladium and gold, palladium and indium, palladium andsulfur, palladium and tellurium, palladium and rhodium, palladium andtungsten, palladium and nickel, palladium and tin, palladium and copper,palladium and ruthenium, palladium and lead, palladium and germanium,cobalt, rhodium, ruthenium, osmium, and iridium.
 10. The catalystcomposite according to claim 5, wherein the extruded activatedcarbonaceous material comprises a first set of pores having a porediameter of at least about 40 Å and at most about 100 Å with a porosityof at least about 0.2 cc/g, and a second set of pores having a porediameter of at least about 5,000 Å and at most about 20,000 Å with aporosity of at least about 0.4 cc/g
 11. The catalyst composite accordingto claim 5, wherein at least about 38% of total Hg porosity occurs in athird set of pores having a diameter of about 1,000 Å and larger in theextruded activated carbonaceous material.
 12. A method of making acatalyst composite: mixing at least one carbonaceous material and aliquid to form a mixture; extruding the mixture into a shaped material;optionally drying the shaped material; heat treating the shaped materialat a temperature from about 600° C. to about 1,500° C. to provide acatalyst support, wherein the catalyst support has at least about 40% oftotal Hg porosity in pores having a diameter of about 200 Å and larger;and contacting a precious metal catalyst with the catalyst support. 13.The method according to claim 12, wherein the catalyst support comprisesa set of pores having a pore diameter of at least about 40 Å and at mostabout 100 Å with a porosity of at least about 0.15 cc/g, and another setof pores having a pore diameter of at least about 5,000 Å and at mostabout 20,000 Å with a porosity of at least about 0.3 cc/g
 14. The methodaccording to claim 12, wherein the shaped material is in the form of oneor more from the group consisting of spheres, tablets, cylinders, stars,tri-lobes, quadra-lobes, pellets, granules, honeycombs, and cubes. 15.The method according to claim 12, wherein the shaped material comprisesless than about 3% by weight free moisture.
 16. The method according toclaim 12, wherein mixing is conducted for a time of about 5 minutes ormore and about 100 minutes or less and the shaped material is heattreated at a temperature from about 700° C. to about 1,000° C.
 17. Amethod of purifying a crude polycarboxylic aromatic acid composition,comprising: contacting the crude polycarboxylic aromatic acidcomposition with a catalyst composite comprising an extruded activatedcarbonaceous material comprising a first set of pores having a porediameter of at least about 40 Å and at most about 100 Å with a porosityof at least about 0.15 cc/g, and a second set of pores having a porediameter of at least about 5,000 Å and at most about 20,000 Å with aporosity of at least about 0.3 cc/g; and a metal catalyst.
 18. Themethod according to claim 17, wherein the crude polycarboxylic aromaticacid composition comprises terephthalic acid, isophthalic acid and2,6-naphthalene dicarboxylic acid.
 19. The method according to claim 17,wherein the crude polycarboxylic aromatic acid composition comprisesterephthalic acid and at least one of undesirable coloring componentsand 4-carboxy benzaldehyde.
 20. The method according to claim 17,wherein the crude polycarboxylic aromatic acid composition is contactedwith the catalyst composite at a temperature from about 100° C. to about350° C. under a pressure from about 150 psig to about 1,600 psig.
 21. Amethod of purifying a crude polycarboxylic aromatic acid composition,comprising: contacting the crude polycarboxylic aromatic acidcomposition with a catalyst composite comprising an extruded activatedcarbonaceous material having pores and wherein at least about 40% oftotal Hg porosity occurs in pores having a diameter of about 200 Å andlarger; and a metal catalyst.
 22. The method according to claim 21,wherein the crude polycarboxylic aromatic acid composition comprisesterephthalic acid, isophthalic acid and 2,6-naphthalene dicarboxylicacid.
 23. The method according to claim 21, wherein the crudepolycarboxylic aromatic acid composition comprises terephthalic acid andat least one of undesirable coloring components and 4-carboxybenzaldehyde.
 24. The method according to claim 21, wherein the crudepolycarboxylic aromatic acid composition is contacted with the catalystcomposite at a temperature from about 100° C. to about 350° C. under apressure from about 150 psig to about 1,600 psig.
 25. The methodaccording to claim 21, wherein at least about 34% of total Hg porosityoccurs in pores having a diameter of about 5,000 Å and larger in theextruded activated carbonaceous material.
 26. A method of purifying acrude amine composition or a crude alkynol amine composition,comprising: contacting the crude amine composition or the crude alkynolamine composition with a catalyst composite comprising a catalystsupport comprising an extruded activated carbonaceous materialcomprising a first set of pores having a pore diameter of at least about40 Å and at most about 100 Å with a porosity of at least about 0.15cc/g, and a second set of pores having a pore diameter of at least about5,000 Å and at most about 20,000 Å with a porosity of at least about 0.3cc/g; and a metal catalyst.
 27. The method according to claim 26,wherein the crude amine composition or the crude alkynol aminecomposition comprises a crude aromatic amine composition, a crudearomatic alkynol amine composition, a crude aliphatic amine composition,or a crude aliphatic alkynol amine composition.
 28. The method accordingto claim 26, wherein at least about 38% of total Hg porosity occurs in athird set of pores having a diameter of about 1,000 Å and larger in theextruded activated carbonaceous material.